Form fill seal packaging method and apparatus for compressible goods

ABSTRACT

The disclosure relates to a method and apparatus for compressing woven material or other compressible material, such as, but not limited to, a comforter set or bedding set. The bedding set or other woven material is placed into a reclosable storage bag through the open bottom thereof. The bag is compressed by a compression apparatus and the open bottom of the storage bag is sealed shut. The result is a package with reduced volume, which reduces shipping and display costs, and is more aesthetically attractive to the consumer.

BACKGROUND OF THE DISCLOSURE

This application claims priority under 35 U.S.C. §119(e) of provisional patent application Ser. No. 61/359,133, filed on Jun. 28, 2010; provisional application Ser. No. 61/304,734, filed on Feb. 15, 2010, the contents of all of which are hereby incorporated by reference in their entirety. Additionally, this application is a continuation-in-part of application Ser. Nos. 12/823,823 and 12/823,331, both filed Jun. 25, 2010 and both claiming priority under 35 U.S.C. §119(e) of said provisional patent application Ser. No. 61/304,734, filed on Feb. 15, 2010, the contents of all of which are hereby incorporated by reference in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a form fill and seal method and apparatus for producing compact shipping for woven fabric articles or compressible materials, such as, but not limited to, bedding materials.

DESCRIPTION OF THE PRIOR ART

In the prior art, it is well known to package woven fabric articles or compressible materials, such as bedding material, in a package or bag made from polymeric or similar material. However, the resulting packaging can be bulky which increases transportation, storage and display costs throughout the chain of commerce. Similarly, a consumer may be less prone to buy an unwieldy package.

The storage of polymeric bag within a box is disclosed in U.S. Pat. No. 7,588,160, entitled “Combined Storage Apparatus”, issued on Sep. 15, 2009 to Chen.

While the embodiments disclosed in parent application Ser. Nos. 12/823,823 and 12/823,331, both filed Jun. 25, 2010 and entitled “Method and Apparatus for Compressing and Holding in Compression Woven Fabric Articles” have been satisfactory for their intended purposes, further improvements are desired, such as increasing the manufacturing speed and possibly increasing the automation of the method and apparatus.

SUMMARY AND OBJECTS OF THE DISCLOSURE

It is therefore an object of the present disclosure to provide further improvements in a method and apparatus for compressing woven fabric articles or compressible materials, such as, but not limited to, bedding materials, in order to provide a compact and aesthetically pleasing package. These improvements may include increasing the manufacturing speed and possible increasing the automation of the method and apparatus.

This and other objects are attained by the present disclosure by providing a method and apparatus wherein a series of plastic storage bags with open bottoms are provided. The plastic storage bags are typically of the type with a reclosable zipper (but may be a plain closure or a non-reclosable closure, such as with a hard seal sealing the top edges of the front and rear walls together), and typically provided in a successive chain configuration, a stacked configuration, a wicketed configuration or a similar configuration. The compressible materials are placed into an open bottom of a plastic storage bag. The compressible material and plastic storage bag are compressed, typically with a pneumatic or hydraulic apparatus. After the compression step has been performed, the bottom is sealed closed thereby retaining the package in its compressed state.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects and advantages of the disclosure will become apparent from the following description and from the accompanying drawings, wherein:

FIG. 1 is a perspective view of an embodiment of the compression apparatus of the present disclosure, implementing the compression step in the vertical direction.

FIG. 2 is a perspective view of a stack of open bottom zippered packages or bags in a wicketed configuration.

FIG. 3 is a plan view of an embodiment for providing packages or bags from a wicketed stack in a vertical direction to a compression device which implements compression in the horizontal direction.

FIG. 4 is a side or cross-sectional view of a blanket or similar compressible material with the package or bag and positioned within the compression apparatus prior to compression in the horizontal direction.

FIG. 5 is a side or cross-sectional view of a blanket or similar compressible material with the package or bag, after the compression step in the horizontal direction has been performed by the compression apparatus, with the seal jaws preparing to form the seal in the package or bag.

FIG. 6 is a perspective view of an embodiment for providing packages or bags from a wicketed stack in a horizontal direction to a compression device which implements compression in the horizontal direction.

FIG. 7 illustrates a chain of inverted packages or bags with the open bottoms facing upwardly.

FIG. 8 illustrates a chain of inverted packages being removed from a container, filled with compressible goods and sealed shut.

FIG. 9 illustrates a chain of packages being removed from a container, and configured into a horizontal configuration, in anticipation of subsequent filling, compressing and sealing.

FIG. 10 illustrates the extrusion of zipper profiles onto a film for the production of the packages or bags used in an embodiment of the present disclosure.

FIG. 11 illustrates the folding of the film to join the profiles of the zipper.

FIG. 12 illustrates the folded film with cross-seals, thereby forming the open bottom bags of an embodiment of the present disclosure.

FIG. 13 is a perspective view of an embodiment of the present disclosure. configured as a horizontal compression fill rotary seal apparatus.

FIG. 14 is a perspective view of an embodiment of the present disclosure, configured as a horizontal funnel fill seal apparatus.

FIG. 15 is a perspective view of an embodiment of the present disclosure, configured as a horizontal funnel fill seal apparatus with ninety degrees to the feed conveyors.

FIG. 16 is a perspective view of an embodiment of the present disclosure, configured as a horizontal pre-compression filling apparatus with sealing station with in-line conveyors.

FIG. 17 is a perspective view of an embodiment of the present disclosure, configured as a horizontal funnel filling open zipper apparatus.

FIG. 18 is a perspective view of an embodiment of the present disclosure, configured as a horizontal compression index loading apparatus.

FIG. 19 is a perspective view of a pre-compression inserter device which is adaptable to at least the illustrated embodiments of FIGS. 13, 16 and 18.

FIG. 20 is a perspective view of a final compression and sealing device which is adaptable to at least the illustrated embodiments of FIGS. 13, 14, 15, 16, 17 and 18.

FIGS. 21A-C form a series of perspective views showing a compression device for various illustrated embodiments of the present disclosure.

FIG. 22 is a perspective view illustrating an apparatus of the present disclosure, using guide rails to guide and open the packages or bags.

FIG. 23 further illustrates the use of guide rails, in combination with packages or bags with perforations for the removal of a portion of the packages or bag.

FIG. 24 further illustrates the use of guide rails to open the packages or bags.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that FIG. 1 is a perspective view of pressing apparatus 10 of the present disclosure. The apparatus of FIG. 1 was disclosed in the above-referenced parent applications of the present application. Pressing or compression apparatus 10 includes a frame 12, typically made from metal, which further includes a ground-engaging rectangular base 14, upright vertical elements 16 at the corners, and an upper horizontal portion 18. Tray 20 is positioned on rectangular base 14. Tray 20 typically includes an extended floor 21 which can serve as a feeding ramp. Tray 20 further typically includes first and second side elements 22, 24 which are inwardly and outwardly adjustable to accommodate different sizes of packages and may be configured as being movable. Tray 20 further typically includes rear element 25. Rear element 25 may be hinged to provide further access to storage bag 104 (described hereinafter) and to allow the storage bag 104 (including compressible material 102) to be pushed out of the rear of pressing or compression apparatus 10. The use of first and second side elements 22, 24, along with rear element 25, allows the storage bag 104 (including compressible material 102) to be compressed into a controlled shape, with the contents typically remaining very flat and smooth. Additionally, different shapes for the resulting product may be achieved by placing elements into different configurations.

Compression arm 30 reciprocates vertically toward and away from tray 20. Compression arm 30 includes flat compression plate 32 (typically sixteen by sixteen inches for applications involving bedding materials) which moves toward and away from tray 20 and impinge against the storage bag 104, with compressible material 102 contained therewithin. The compression plate 32 provides a compression surface and is connected by first and second horizontal cross-beams 34, 36 which are, in turn, connected to respective first and second vertical guide rods 38, 40 which are engaged by respective first and second guide apertures 39, 41 and thereby constrained to vertical motion. Vertical drive rod 37 is connected between pneumatic drive 48 and compression plate 32. Pneumatic drive 48 thereby moves compression plate 32 vertically and applies a force to compression plate 32, thereby causing a compression force to be exerted across the area of compression plate. It has been found that a force of at least 2.5 to 3.5 pounds per square inch typically is required for sufficient compression of most compressible materials, such as, but not limited to, woven textile or cloth, particularly those frequently used for bedding materials.

While FIG. 1 illustrates the compression taking place in a vertical direction. Other embodiments may implement compression in the horizontal direction. Additionally, in all of the illustrated embodiments, while not illustrated, a small amount of vacuum may be applied during compression in order improve the appearance of the compressed material.

FIG. 2 illustrates a stack 200 of storage bags 104. Sealable storage bags 104 include front and rear walls 106, 108, typically of transparent polymeric material, with an airtight or leak-resistant reclosable zipper 110 at a top or first end thereof, with first and second interlocking profiles 112, 114 which can be selectively opened (separated) or closed (interlocked) by movement of an optional slider (not shown). The stack 200 is typically provided with the first and second interlocking profiles 112, 114 interlocked with each other. A pre-activated peel seal 115 may be provided on the product side of zipper 110 to further insure the air-tight characteristics of the top of the storage bag 104. While not shown in FIG. 2, one of the front and rear walls 106, 108 may include a reclosable air valve with an open position which allows air to pass freely therethrough and a closed position which provides an airtight or leak-resistant configuration. As shown in FIG. 2, sealable storage bags 104 are initially provided with an open bottom (or opening) 120 at a second end thereof, with rear wall 108 including a supporting portion 122 below a perforated or otherwise tearable line 124. The supporting portion 122 includes first and second apertures 126, 128 which align with like first and second apertures 126, 128 of successive storage bags 104, thereby allowing respective first and second pins 130, 132 to pass therethrough, resulting in what is known to those skilled in the art as a wicketed configuration. This allows the storage bags 104 to be provided from the stack 200 by tearing along perforated or otherwise tearable lines 124, thereby typically resulting in front and rear walls 106, 108 of substantial equal length. Storage bags 104 may be provided in different ways, such as, but not limited to, in a stack free of connection with each other, or in a chain-type configuration wherein the sides of subsequent storage bags are connected to each other.

FIGS. 3, 4 and 5 illustrate a sequence of compressing and sealing package 104 with compressible material 102 therewithin. Individual storage bags 104 are taken from wicketed stack 200. Compressible material 102, such as, but not limited to, a comforter set, is placed into an inverted storage bag 104 (with the first and second interlocking profiles 112, 114 interlocked with each other) through the upwardly facing open bottom 120 thereof, and dropped, typically by gravity, between compression plate 32 and fixed vertical wall 14′ of horizontally oriented compression apparatus 10. The storage bag 104 and the compressible material 102 are then compressed horizontally between compression plate 32 and fixed vertical wall 14′ as shown in FIG. 5. As further shown in FIG. 5, then first and second seal bars 50, 52 engage and seal the lower edges of front and rear walls 106, 108, thereby forming a bottom air-tight seal 140 so as to maintain the compressible material 102 in a compressed state within the air-tight storage bag 104. The compression plate 32 may then be retracted to the position shown in FIG. 3 and lower hinged plate 25′ lowered so as to allow the storage bag 104, with compressible material 102 therein, to drop from the compression apparatus.

Compressible material 102 may further include, but is not limited to, comforters, pillows, blankets, quilts, bedspreads, mattress pads, bath towels beach towels. dish towels, kitchen towels, toilet lid and tank covers, bath accessories, bedding accessories, sleeping bags, duffel bags, toys, apparel, fabrics, cotton batting, and fill materials (such as polyester fill).

In the embodiment shown in FIG. 6, the stack 200 of storage bags 104 is provided in a wicketed configuration, and in a vertical orientation. The orientation can further be considered to be inverted in that the open bottoms 120 are facing upwardly. The swing arm 300 is configured to swing through a range of 180 degrees and, by using a vacuum or similar device, takes a single storage bag 104 from stack 200 and moves the storage bag 104 in a generally horizontal direction to horizontally oriented compression apparatus 10, as accessed through hinged side door 60. A process similar to that shown in FIG. 5 is then typically used to insert the compressible material 102 into storage bag 104 and form the bottom seal.

FIG. 7 illustrates a connected chain of inverted storage bags 104, with the open bottoms 120 facing upwardly. The inverted storage bags 104 are connected to adjacent inverted storage bags 104 by their respective edges. The downward facing tops of the storage bags 104 include reclosable zippers 110, but the reclosable zippers may be replaced with non-vacuum laminate film.

FIG. 8 illustrates a connected chain of inverted storage bags 104, wherein the storage bags 104 are stored in a horizontal configuration in stack 200 and subsequently mounted on spreader rails 410, 412 (typically by passing spreader rails 410, 412 through respective loops formed in front and rear walls 106, 108) and conveyed in a vertical configuration. As the spreader rails 410, 412 engage the front and rear walls 106, 108, respectively, increasing the distance between spreader rails 410, 412 can serve to spread apart the opening of the storage bag 104.

FIG. 9 is similar to FIG. 8, but the storage bags 104 are conveyed in a horizontal configuration on table 404.

As shown in FIGS. 10, 11 and 12, the first and second zipper profiles 112, 114 can be extruded on a single sheet of web which is folded to align the zipper profiles 112, 114 with each other, and further to form front and rear walls 106, 108. Cross seals 117 are formed to provide the separate storage bags 104 as shown in FIG. 12 Cross seal 117′ illustrates an incomplete cut in the cross seal, thereby allowing a chain to be formed by successive storage bags 104.

FIG. 13 illustrates an embodiment of form fill seal (FFS) apparatus 500 with horizontal pre-compression ninety degrees rotate seal capability. Chain linked open-bottom storage bags 104 are indexed horizontally while lying flat and guided by the zipper profiles 112, 114. The compressible material 102 is also indexed along parallel to the storage bag movement. At the fill station 502, the compressible material 102 enters the pre-compression inserter device 504 (see FIG. 19) and is compressed between platens 507, 509 and pushed by automated pusher arm 520 into the open bag which is between the platens 508, 510 of the final compression and sealing device 506 (see FIG. 20). The platens 508, 510 complete the compression, the storage bag 104 is rotated ninety degrees about a vertical axis, and sealer 512 (similar to the seal bars 50, 52 of FIGS. 3 and 5) seals the open bottom of storage bag 104.

FIG. 14 illustrates an embodiment of form fill seal (FFS) apparatus 500 with a horizontal funnel filling sealing station with in-line conveyors. Chain-linked open-bottom storage bags 104 are indexed horizontally while lying flat and guided by the zipper profiles 112, 114. The compressible material 102 is likewise indexed parallel to the movement of the storage bags 104. At the fill station 502, the compressible material 102 is pushed through a sizing funnel 516 by plate 511, thereby performing preliminary compression, and into the opened storage bag 104 that is placed between two horizontal conveyor belts 513, 515 that are aligned in the same direction as the movement of the compressible material 102 and the storage bag 104. The conveyor belts 513, 515 are angled together, so that when they index, the conveyor belts 513, 515 continue to compress the storage bag 104 to expel the excess air. The almost fully compressed filled storage bag 104 continues to index in the same direction into a final compression and sealing device 506 (see FIG. 20) which further compresses and seals the storage bag 104. Final compression and sealing device 506 may include side containment walls 518 which assist with the final sizing of storage bag 104.

FIG. 15 illustrates an embodiment of form fill seal apparatus 500 with a horizontal funnel filling sealing station with ninety degrees to feed conveyor. Chain-linked open bottom storage bags 104 are indexed horizontally while lying flat and guided by the zipper profiles 112, 114. The compressible material 102 is also indexed parallel to the storage bag movement. At the fill station 502, the compressible material 102 is pushed through a sizing funnel 516 by plate 511 and into the opened storage bag that is placed between two horizontal conveyor belts 513, 515 that are aligned perpendicular to the direction of the movement of the storage bag 104 and the compressible material 102. Similar to the embodiment of FIG. 14, the conveyor belts are angled together, so that when they index, the conveyor belts continue to compress the storage bag 104 to expel the compressed air. The almost fully compressed filled storage bag 104 continues to index in the same direction into a final compression and sealing device 506 (see FIG. 20) which further compresses and seals the storage bag 104. Final compression and sealing device 506 may include side containment walls 518 which assist with the final sizing of storage bag 104.

FIG. 16 illustrates an embodiment of form fill seal apparatus 500 with horizontal pre-compression with a sealing station in line with the conveyors. Chain-linked open bottom storage bags 104 are indexed horizontally while lying flat and guided by the zipper profiles 112, 114. The compressible material 102 is indexed along parallel to the storage bag movement. At the fill station 502, the compressible material 102 enters the pre-compression inserter device 504 (see FIG. 19) is compressed between platens 507, 509. While plates 507, 509 are in the compressed position, the pre-compression insertor device 504 moves perpendicularly to the bag motion into the open bottom of the storage bag 104. An automated pusher arm pushes 520 the filled partially compressed storage bag 104 from the platens 507, 509 and between the two horizontal conveyor belts 513, 515 that are aligned in the same direction as the movement of the compressible material 102 and the storage bag 104. The conveyor belts 513, 515 are angled together, so that when they index, the conveyor belts 513, 515 continue to compress the storage bag 104 to expel the excess air. The almost fully compressed filled storage bag 104 continues to index in the same direction into a final compression and sealing device 506 (see FIG. 20) which further compresses and seals the storage bag 104. Final compression and sealing device 506 may include side containment walls 518 which assist with the final sizing of storage bag 104.

FIG. 17 illustrates an embodiment of form fill seal apparatus 500 with horizontal funnel filling through an open zipper. Chain-linked open-bottom storage bags 104 are indexed horizontally while lying flat. The compressible material 102 is likewise indexed parallel to the movement of the storage bags 104. At the fill station 502, the compressible material 102 is pushed through a sizing funnel 516 by plate 511, through the opened zipper profiles 112, 114 and the opened storage bag 104 that is placed between two horizontal conveyor belts 513, 515 that are aligned in the same direction as the movement of the compressible material 102 and the storage bag 104. The conveyor belts 513, 515 are angled together, so that when they index, the conveyor belts 513, 515 continue to compress the storage bag 104 to expel the excess air. The almost fully compressed filled storage bag 104 continues to index in the same direction into a final compression and sealing device 506 (see FIG. 20) which further compresses and closes the zipper profiles 112, 114 of the storage bag 104. Final compression and sealing device 506 may include side containment walls 518 which assist with the final sizing of storage bag 104.

FIG. 18 illustrates an optional loading device with horizontal compression and index loading. Compressible material 102 loaded onto an indexing feeding device which is configured as conveyor belt 540 with partitions 542 spaced at package-width intervals. This apparatus further includes pre-compression inserter device 504 (see FIG. 19) and final compression and sealing device 506 (see FIG. 20) as previously described.

FIG. 19 illustrates the pre-compression inserter device 504 which is incorporated into the previously described embodiments of FIGS. 13, 16 and 18. Platens 507 and 509 are used to grasp and initially or preliminarily compress compressible material 102. Compressible material 102 is then urged out of device 504 by automated pusher arm 520 (with a pusher plate) into the open storage bag 104.

FIG. 20 illustrates the final compression and sealing device 506 which is incorporated into the previously described embodiments of FIGS. 13-16, 18 and 19. After the final compression of compressible material 102 with storage bag 104 (with an open bottom) is performed between platens 508, 510, the device 506 can, depending upon the requirements of the specific embodiment, rotate 90 degrees about a vertical axis in order to present the open bottom film-to-film section to the sealer 512.

FIGS. 21A-21C show a further improvement to final compression and sealing device 506 wherein side plates 522, 524 are provided. A similar back plate (not shown) may also be provided. The movable side plate 522, 524 pivot inwardly from both sides toward the storage bag 104. As they pivot inwardly, they can also slide upwardly to allow for clearance as the top platen 508 compresses the storage bag 104. The side plates 522, 524 function as constraints to compress the open bottom bag symmetrically, squeezing from both sides simultaneously rather than from just on side, or, only from the top. This provides increased uniformity in the control of the compression of the storage bag containing compressible material 102, thereby, in some applications, perhaps producing a more aesthetically pleasing, less wrinkled product.

FIGS. 22-24 illustrate how spreader rails 410, 412 can be attached to front and rear walls 106, 108 of storage bag 104, thereby allowing the increasing of distance between spreader rails 410, 412 to open the storage bag 104 as desired. Additionally, as shown in FIG. 24, spreader rails 410, 412 may be hollow with radially oriented apertures 414 in order to allow compressed air to be injected into spreader rails 410, 412, thereby reducing friction between the spreader rails 410, 412 and the front and rear walls 106, 108 of storage bag 104, thereby enabling the rapid movement of the storage bags 104 along spreader rails 410, 412.

The resulting storage bags 104, with the compressed material 102 sealed therewithin, can be sold within a retail establishment, and may include the configuration disclosed in parent application Ser. Nos. 12/823,823 and 12/823,331.

Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims. 

1. A method, including the steps of: providing a package with a first end and a second end, including a closure at the first end and an opening at the second end; placing compressible material within the package through the opening; compressing the package thereby expelling a portion of air from the package; and sealing the opening.
 2. The method of claim 1, wherein the closure is a reclosable zipper.
 3. The method of claim 2 wherein the compressible material includes woven material.
 4. The method of claim 1 wherein the compressible material includes textile or cloth.
 5. The method of claim 4 wherein the step of compressing the package is performed in the absence of a vacuum being applied to the package.
 6. The method of claim 4 wherein the step of compressing the package is performed with vacuum being applied to the package.
 7. The method of claim 5 wherein the step of compressing is performed with at least 2.5 pounds per square inch of force applied to the package.
 8. The method of claim 5 wherein the step of compressing is performed with at least 3.5 pounds per square inch of force applied to the package.
 9. The method of claim 5 wherein the reclosable zipper includes two interlocking profiles which, when interlocked, form a leak-resistant seal.
 10. The method of claim 9 wherein a peel seal is provided adjacent to the reclosable zipper.
 11. The method of claim 1 wherein the step of providing a package includes the step of providing a series of packages.
 12. The method of claim 11 wherein the step of providing a series of packages includes the step of providing a stack of packages include apertures through which at least one pin passes.
 13. The method of claim 12 wherein the step of providing a stack of packages includes provided a wicketed stack of packages.
 14. The method of claim 11 wherein the step of providing a series of packages includes the step of providing a sequential chain of packages, wherein packages are attached to adjacent packages.
 15. The method of claim 14 wherein the sequential chain of packages is provided in a stack.
 16. The method of claim 11 including the step of providing the packages in an inverted vertical configuration.
 17. The method of claim 16 wherein the step of placing compressible material within the package through the opening is performed vertically.
 18. The method of claim 11 including the step of providing the packages a horizontal configuration.
 19. The method of claim 18 wherein the step of placing compressible material within the package through the opening is performed horizontally.
 20. The method of claim 1 further including the step of extruding first and second zipper profiles onto a single sheet of web and folding the web align the first and second zipper profiles with each other and to form walls of the package.
 21. The method of claim 1 wherein the packages and the compressible material are provided horizontally in a first direction, and wherein the step of placing compressible material within the package through the opening is performed horizontally in a second direction, perpendicular to the first direction.
 22. The method of claim 21 further including a preliminary compression step prior to the step of placing compressible material within the package through the opening.
 23. The method of claim 21 wherein the preliminary compression step is performed by a funnel shaped apparatus.
 24. A packaging of compressible material, comprising: a package including front and rear walls, a mouth with a reclosable zipper; and a sealed bottom; compressible material contained within the package, the compressible material being in a compressed state resulting from a compressive force of at least 2.5 pounds per square inch, and the package being at least partially evacuated of air, the compressible material having been inserted into the package prior to sealing of the bottom; wherein the packaging is sold in a retail establishment.
 25. The packaging of claim 24 wherein the compressible material includes woven material.
 26. The packaging of claim 24 wherein the compressible material includes textile or cloth.
 27. The packaging of claim 25 wherein the reclosable zipper includes two interlocking profiles which, when interlocked, form a leak resistant seal. 